Container Insert for Reducing Headspace

ABSTRACT

An insert for a container comprising an insert which is adapted to be inserted into the opening of a container, and having an aperture, projecting axially outwardly thereof, said aperture presenting an inner wall surface defining a channel through which a stream of liquid may flow, and said insert having at least one chamber which extends into the liquid product of said container when the insert is inserted into said container.

FIELD OF THE INVENTION

The present invention relates generally to an insert for liquid containers. More specifically, the present invention relates to a nozzle insert which reduces headspace within the container.

BACKGROUND OF THE INVENTION

As liquid compositions are packaged into consumer ready packages, air is commonly trapped at the top of the container before it can be sealed. The air trapped at the top of the container (headspace) results in an air bubble when the container is sealed, which disrupts the composition within the bottle if the bottle is rotated or its orientation is changed. In instances where a specific design is created within the liquid composition in the container, the air bubble can cause damage to the design during shipping. Headspace can generally be reduced by “topping off” the container with a sufficient amount of the composition as to prevent air from remaining at the top of the container. However, this technique is difficult to automate, and therefore must typically be performed by hand. Additionally, “topping off” often results in overflow of the liquid composition, which becomes costly and risks overall quality of the packaged liquid product.

A known method for eliminating headspace is to vent liquid-filled containers. One technique involves a pressure system comprising pieces of rubber, metal springs, and/or soft films (typically vinyl chloride) being used to lift and open vent orifices in a closure when internal pressure reaches a given threshold value. The venting method is heavily dependent on the type of liquid composition being vented in order to be operable. It also limits design options and prevents optimal dispensing of the liquid composition. Another technique is to provide elaborate apertures in a closure whereby gases may leave the system but liquid losses are minimized. A third system, which may be called the pinorifice system, employs one or more tiny orifices in rubber, metal or plastic diaphragms which render the material permeable to gases. Yet another system, commonly called a positive displacement pump, or piston system, employs a mechanism which pushes a composition to the top of a container via a rising piston or pump. However, none of the aforementioned methods effectively eliminates headspace from a container.

Generally, these methods employ a venting closure at the top of the neck of the container. Such a configuration requires manual expulsion of gases after filling, by way of a pump or compression of the container, which forces gases through the venting material. These methods are vulnerable to incomplete expulsion of gases and often result in backflow of gases into the container. Particularly, where gases are expelled by compression of a flexible container, when the container is allowed to return to its uncompressed position, some gas is likely to migrate back into the container.

Therefore, a need still exists for an insert which reduces headspace during packaging. A need also exists to allow easy dispensing, from the same venting closure, of the contents of the package by a consumer.

SUMMARY OF THE INVENTION

The present invention meets the aforementioned needs by providing an insert for a container comprising an insert which is adapted to be inserted into the opening of a container, and having an aperture, projecting axially outwardly thereof, said aperture presenting an inner wall surface defining a channel through which a stream of liquid may flow, and said insert having at least one chamber which extends into the liquid product of said container when the insert is inserted into said container.

While the invention will be described in connection with certain embodiments, it will be understood that the invention is not limited to these embodiments. On the contrary, the invention includes all alternatives, modifications, and equivalents as may be included within the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.

FIG. 1 is a perspective view of the insert described herein;

FIG. 2 a top view of the insert;

FIG. 3 is a cross sectional view according to the arrows B-B in FIG. 2;

FIG. 4 is a cross sectional view according to the arrows A-A in FIG. 3;

FIG. 5 is a cross sectional view of a container fitted with the insert according to the arrows B-B in FIG. 2;

FIG. 5A is a detailed view of the container and insert according to FIG. 5;

FIG. 6 is a cross sectional view of a container fitted with the insert according to the arrows A-A in FIG. 3;

FIG. 6A is a detailed view of the container and insert according to FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

While the specification concludes with claims that particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description.

The term “headspace” as used herein, refers to the space between the opening of the container's dispensing orifice and the liquid composition in the container. Upon reducing headspace to substantially zero, there is essentially no space between the liquid composition and the opening of the dispensing orifice. Therefore, the air bubble typically present due to head space is substantially eliminated.

FIG. 1 shows a perspective view of the insert 1 which is adapted to be inserted into the opening of a container. The insert 1 also comprises an annular flange 2 at its upper portion 5, which prevents the insert 1 from falling into the container reservoir after it is inserted into the container opening. In another embodiment, the flange 2 could be replaced by threads or another securing means. The insert 1 is formed from a resilient material and comprises at least one chamber, but preferably at least two chambers 6, 7 for receiving the displaced liquid composition which flows through the aperture's 3 channel 4 upon insertion into a container, which contains a liquid composition prior to application of the insert 1. The aperture 3 comprises a generally cylindrical opening which extends upwardly towards the dispensing orifice of the container. The aperture 3 is generally located centrally to the insert's vertical axis. The aperture 3 and annular flange 2 accordingly have the appearance of two concentric circles.

FIG. 2 shows a view of the insert 1 from above, showing the upper portion 5, including the annular flange 2, the chambers 6, 7, and the aperture 3. The aperture 3 may further comprise a restrictor 17 to better control dispensing of a liquid product. A restrictor 17 may be suitable depending on the physical properties of the liquid product in the container. More viscous liquid compositions may have a tendency to “spit” from the dispensing orifice of the container in the absence of a restrictor 17. The cylindrical shape of the aperture 3 should extend downwardly along the inner walls of the chamber, creating an indentation along the surface of the walls.

FIG. 3 shows a cross sectional view of the insert 1 along the line B-B of FIG. 2. The chamber walls 11 are generally flat towards their edges and curve inwardly at the medial axis creating a concave indention 10 which extends coaxially upward towards the aperture 3 opening. The flat portion 9 of the chamber maximizes the volume of the chamber 6, while the concave indentation 10 assists in guiding the liquid product upwardly towards the aperture 3 channel 4. The outside surface 8 of the chamber walls 11 are generally cylindrical, which maximizes volume and does not obstruct installation of the insert 1 into a container with a cylindrical orifice. Of course, the general shape of the insert 1 may be modified based upon the container's orifice shape.

FIG. 4 shows a cross sectional view of the insert 1 along the line A-A of FIG. 3. The chambers 6, 7 act as reservoirs and are designed to fill with liquid product upon insertion into the liquid container according to FIGS. 5-6. As shown, the insert 1 may comprise two chambers 6, 7, having a gap 12 between them, which terminate at the formation of the aperture 3. The presence of the gap 12 between each chamber 6, 7 allows for the channel 4 length to be minimized, which improves the flow of the liquid product into the channel 4. Furthermore, as the liquid product in the container is reduced over a usage cycle, the liquid will collect towards the neck of the container when the container is inverted. Providing a gap 12 between the chambers 6, 7 allows the liquid product near the neck of the container to easily flow through gap 12 and into the channel 4, thereby reducing wasted liquid product.

FIGS. 5 and 6 show cross sectional views of a container 16 which is suitable for containing a liquid product, having the insert 1 herein is inserted into the dispensing orifice 18 of the container 16 across the lines B-B and A-A of FIGS. 2 and 3 respectively. FIGS. 5A and 6A provide detailed views of the insert 1 and container 16 combination according to FIGS. 5 and 6 respectively. As discussed hereinbefore, when containers 16 are filled with liquid products on a production line, the liquid product typically does not fill the neck 13 of the container 16, and if sealed, an air bubble forms in the liquid composition and remains in the composition after it is sealed. In order to eliminate this headspace, the insert 1 is placed into the dispensing orifice 18 of the container 16. The chambers 6, 7 displace the liquid product in the container 16 as they are inserted, and the liquid product is forced upward through the insert's 1 channel 4. The overflow from the displaced liquid product collects in the chambers 6, 7. The container 16 cap 23 may be designed to seal the chambers 6, 7 of the insert 1 at an interface 20, 21. The cap 23 may also comprise a lid 22 with a plug 19 to form a resealable interface for dispensing the liquid product.

As mentioned hereinbefore, the insert 1 of the present invention reduces headspace in containers which contain liquid compositions. It is particularly important to reduce headspace in liquid compositions where the pattern or design of the liquid composition is considered to be important. Such products include liquid personal care products which exhibit a pattern or design, including multi-phase skin care products, shampoos, conditioners, and body washes. Additionally, in order for the pattern or design of such liquid products to be visually appreciated, the container should be formed, at least partially, from a transparent material. Suitable materials include glass and plastic materials such as polyethylene, polypropylene, or poly(ethylene terephthalate).

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

1. An insert which is adapted to be inserted into the dispensing orifice of a container comprising: an aperture, projecting axially and outwardly along the vertical axis of the insert, said aperture defining a channel through which a stream of liquid may flow, and said insert having at least one chamber which extends into the liquid product of said container when the insert is inserted into said container.
 2. An insert according to claim 1, wherein said insert comprises at least two chambers, having a gap between said chambers, said gap terminating at said channel.
 3. An insert according to claim 1, wherein said container is a flexible container.
 4. An insert according to claim 3, wherein said container is transparent or semi-transparent.
 5. An insert according to claim 1, wherein said container comprises polyethylene, polypropylene, or poly(ethylene terephthalate).
 6. An insert according to claim 1, wherein said liquid composition exhibits a pattern or design.
 7. An insert according to claim 6, wherein said liquid composition is a multi- phase personal care composition.
 8. An insert to claim 1, wherein said container further comprises a cap.
 9. An insert to claim 8, wherein said cap comprises a plug.
 10. An insert to claim 8 wherein said cap comprises an interface, wherein said interface seals said chambers.
 11. A method for reducing headspace according to the following steps: a) inserting the insert according to claim 1 into said container, said container containing a liquid product; b) displacing said liquid product until the liquid composition flows through said channel and into said chambers; and c) sealing said container. 